# APPENDIX 5-A. DRAFT ENGINEERING ANALYSIS DATA REQUEST SHEETS

TABLE OF CONTENTS

5-A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR

RESIDENTIAL CLOTHES DRYERS

.......................................................................... 2

5-A.2 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR ROOM AIR

CONDITIONERS

.......................................................................................................... 6

5-A.3 DATA REQUESTS FOR STANDARDS RULEMAKING FOR

RESIDENTIAL CLOTHES DRYERS AND ROOM AIR-CONDITIONERS

.......... 12

5-A-i

# DOE seeks average incremental production cost to take basic models in the categories shown

from the current DOE minimum efficiency lev el (or proposed baseline level) to the specified

efficiency level. For those product classes where more than one basic model may exist, please

indicate the minimum and maximum incremental costs that would be incurred across the array of

basic models.

The data sheets are divided by product and contain tables requesting shipment and manufacturer

cost data.

Shipments

For residential clothes dryers and room air conditioners, the AHAM 2005 Fact Book offers

historical shipments data (for both products) and efficie ncy data (for room air conditioners only),

but the information is not disaggregated by produc t class. As shown in the “shipment request”

tables below, DOE hopes to collect both shipments data and shipment-weighted average

efficiency data dating back to 1993. In addition, DOE hopes to collect market share efficiency

( i.e. , data on the distribution of product shipments by eff iciency) for each of the product classes.

Manufacturer Costs

Incremental cost data (in U.S. dol lars) include the materials, labor, and overhead needed to take

basic models from the current minimum DOE baseline efficiency standard to each higher

efficiency level. The depreciation of the conversion capital expenditures is an important

component of the overhead for DOE to understand. Therefore, DOE is requesting information

about conversion capital expenditures by efficiency level.

5-A-1

# 5-A.1 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR

RESIDENTIAL CLOTHES DRYERS

Table A1-1 Residential Clothes Dryer Shipm ent and Shipment-Weighted Average

Efficiency Data

Year Shipments, Domestic + Imports

(Thousands of Units) Shipment-Weighted Average Efficiency

(EF)

Vented Vent-less Vented

Electric

Gas Electric Electric

Gas Standard Compact

120v Compact

240v Compact

240v Combo Standard Compact

120v Compact

240v

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2006



# Table A1-2 Residential Clothes Dryer Market Share Efficiency Data: Vented Electric

Standard and Compact 120v

Vented Electric Standard Vented Electric Compact 120v

Efficiency Bins Market Share for 2005 or 2006* Efficiency Bins Market Share for 2005 or 2006*

(EF) (Percent) (EF) (Percent)

3.01-3.09 3.13-3.19

3.10-3.19 3.20-3.29

3.20-3.29 3.30-3.39

> 3.29 > 3.39

* Total market share percentages should equal 100%.



# Table A1-3 Residential Clothe s Dryer Market Share Efficiency Data: Vented Electric

Compact 240v and Gas

Vented Electric Compact 240v Vented Gas

Efficiency Bins Market Share for 2005 or 2006* Efficiency Bins Market Share for 2005 or 2006*

(EF) (Percent) (EF) (Percent)

2.90-2.96 2.67-2.74

2.97-3.06 2.75-2.84

3.07-3.17 2.85-2.94

> 3.17 > 2.94

* Total market share percentages should equal 100%.



# 5-A-2Table A1-4 Residential Clothes Dryer Manufacturer Cost Data:Vented Electric Standard and Electric Compact 120VProduct Class�Vented Electric StandardVented Electric Compact 120VEfficiency Level123123EF (lb/KWh)3.103.163.39++++3.79Design Options+Average Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Minimum Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Maximum Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Conversion Capital Expenditures ($, Millions)Building CAPXTooling/ EquipmentCAPXOne-Time Product Conversion Expenses ($, Millions)R&DMarketing+Manufacturer respondents should suggest the design option or design option combinations that they believe should be associatedwith each efficiency level.++ DOE was unable to obtain data for any clothes dryers with efficiencies between the standard level of EF = 3.13 and the max available level of EF = 3.79. Therefore, manufacturer respondents shouldsuggest representative intermediate efficiency levels.# Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead.*Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the current Federal standard for residential clothes dryers.5-A-3Table A1-5 Residential Clothes Dryer Manufacturer Cost Data: Vented Electric Compact 240V and GasProduct Class�Vented Electric Compact 240 VVented GasEfficiency Level123123EF (lb/KWh)2.983.073.232.752.773.02Design Options+Average Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Minimum Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Maximum Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Conversion Capital Expenditures ($, Millions)Building CAPXTooling/ EquipmentCAPXOne-Time Product Conversion Expenses ($, Millions)R&DMarketing+Manufacturer respondents should suggest the design option or design option combinations that they believe should be associatedwith each efficiency level.# Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead.*Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the current federal standard for residential clothes dryers.Other Information:1.What depreciation method would your company use to depreciate the conversion capital expenditures? _______________________________________________.Direct material–Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indirect material costs which are attributed to supplies that maybe used in the production process but are not assigned to final products (e.g., lubricating oil for production machinery).Direct labor–The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct laborincludes the fringe benefits of direct laborers such as grouphealth care, as well as overtime pay. Direct labor does not include indirect labor which is defined as the earnings of employees who do not work directly in assembling a product, such as supervisors,janitors, stockroom personnel, inspectors, and forklift operators.Overhead–Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set-up costs, indirect material,expendable tools, maintenance, property taxes, insurance onassets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accounted for by DOE separately).5-A-4Full Production Cost= Direct Material + Direct Labor + Overhead (factory) + DepreciationFull Cost of Product= Full Production Cost + Non-production Costs (SG&A, R&D, interest, and profit)5-A-5

# 5-A.2 ENGINEERING ANALYSIS DATA REQUEST SHEETS FOR

ROOM AIR CONDITIONER S

5-A-6Table A2-1 Room Air Conditioner Market Share Product Class Data (percent)*Without Reverse Cycle (RC) andWithout Reverse Cycle (RC) andWith RC andWith RC andWith Louvered Sides (LS)Without Louvered Sides (LS)With LSWithout LSCasementYear<6k6-8k8-14k14-20k>20k<6k6-8k8-14k14-20k>20k<20k>20k<14k>14kOnlySlider2000200120022003200420052006* Total market share percentages for each year should equal 100%.Table A2-2 Room Air Conditioner Shipment-Weighted Efficiency Data (EER)Without Reverse Cycle (RC) andWithout Reverse Cycle (RC) andWith RC andWith RC andWith Louvered Sides (LS)Without Louvered Sides (LS)With LSWithout LSCasementYear<6k6-8k8-14k14-20k>20k<6k6-8k8-14k14-20k>20k<20k>20k<14k>14kOnlySlider2000200120022003200420052006Table A2-3 Room Air Conditioner Market Share EfficiencyData: Without Reverse Cycle and With Louvered SidesLess than 6,000 Btu/h6,000 to 7,999 Btu/h8,000 to 13,999 Btu/h14,000 to 19,999 Btu/h20,000 Btu/h and moreEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forBins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*(EER)(percent)(EER)(percent)(EER)(percent)(EER)(percent)(EER)(percent)9.7-10.09.7-10.09.8-10.09.7-10.08.5-8.910.1-10.510.1-10.510.1-10.510.1-10.59.0-9.410.6-11.010.6-11.010.6-11.010.6-11.09.5-9.9> 11.0> 11.0> 11.0> 11.0> 9.9* Total market share percentage should equal 100%.5-A-7Table A2-4 Room Air Conditioner Market Share Efficiency Data: Without Reverse Cycle andWithout Louvered SidesLess than 6,000 Btu/h6,000 to 7,999 Btu/h8,000 to 13,999 Btu/h14,000 to 19,999 Btu/h20,000 Btu/h and moreEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forBins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*(EER)(percent)(EER)(percent)(EER)(percent)(EER)(percent)(EER)(percent)9.0-9.49.0-9.48.5-8.98.5-8.98.5-8.99.5-9.99.5-9.99.0-9.49.0-9.49.0-9.410.0-10.410.0-10.49.5-9.99.5-9.99.5-9.9> 10.4> 10.410.0-10.4> 9.910.0-10.4>10.4>10.4* Total market share percentage should equal 100%.Table A2-5 Room Air Conditioner Market Share EfficiencyData: With Reverse CycleWith Louvered Sides,With Louvered Sides,Without Louvered Sides,Without Louvered Sides,Less than 20,000 Btu/h20,000 Btu/h and moreLess than 14,000 Btu/h14,000 Btu/h and moreEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forEfficiencyMarket Share forBins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*Bins2006 or 2007*(EER)(percent)(EER)(percent)(EER)(percent)(EER)(percent)9.0-9.48.5-8.98.5-8.98.0-8.49.5-9.99.0-9.49.0-9.48.5-8.910.0-10.49.5-9.99.5-9.99.0-9.410.5-10.9> 9.9> 9.99.5-9.9> 10.9>9.9* Total market share percentage should equal 100%.Table A2-6 Room Air Conditioner Market Share Efficiency Data: Casement UnitsCasement-OnlyCasement-SliderEfficiencyMarket Share forEfficiencyMarket Share forBins2006 or 2007*Bins2006 or 2007*(EER)(percent)(EER)(percent)8.7-9.09.5-9.99.1-9.510.0-10.49.6-10.010.5-10.9> 10.0> 10.9* Total market share percentage should equal 100%.5-A-8

# Table A2-7 Room Air Conditioner Manufacturer Cost Data

Product Class � Without Reverse Cycle and with

Louvered Sides, less than 6,000 Btu/h Without Reverse Cycle an d With Louvered Sides,

8000 - 13,999 Btu/h

Efficiency Level 1 2 3 4 1 2 3 4

EER 10.2 10.7 11.2 11.6 10.3 10.8 11.3 11.8

Average Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Minimum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Maximum Incremental Costs ($ Per Unit)*

Material

Labor

Overhead#

Conversion Capital Expenditures ($, Millions)

Building CAPX

Tooling/ Equipment

CAPX

One-Time Product Conversion Expenses ($, Millions)

R&D

Marketing

# Depreciation on the conversion capital expenditure should NOT be included in the incremental overhead.

* Incremental costs per unit should be reported relative to the baseli ne unit’s cost. The baseline unit complies with the fede ral

standard for room air conditioners and is equal to an EER of 9.7 Btu/h/W for a unit without reverse cycle and with louvered sid es

and with a capacity of less than 6,000 Btu/h, an EER of 9.8 Btu /h/W for a unit without reverse cycle and with louvered sides an d

with a capacity of 8,000 to 13,999 Btu/h, and an EER of 8.5 Btu /h/W for a unit without reverse cycle and with louvered sides an d

with a capacity of 20,000 Btu/h and more.



# 5-A-9Table A2-8 Room Air Conditioner Manufacturer Cost Data, continuedProduct Class�Efficiency LevelWithout Reverse Cycle and withWithout Reverse Cycle and Without LouveredLouvered Sides, 20,000 Btu/h and moreSides, 8000 - 13,999 Btu/h1231234EER9.09.510.09.09.510.010.5Average Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Minimum Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Maximum Incremental Costs ($ Per Unit)*MaterialLaborOverhead#Conversion Capital Expenditures ($, Millions)Building CAPXTooling/ EquipmentCAPXOne-Time Product Conversion Expenses ($, Millions)R&DMarketingOther Information:1.What depreciation method would your company use to depreciate the conversion capital expenditures? _______________________________________________.Direct material–Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indirect material costs which are attributed to supplies that maybe used in the production process but are not assigned to final products (e.g., lubricating oil for production machinery).Direct labor–The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct laborincludes the fringe benefits of direct laborers such as grouphealth care, as well as overtime pay. Direct labor does not include indirect labor which is defined as the earnings of employees who do not work directly in assembling a product, such as supervisors,janitors, stockroom personnel, inspectors, and forklift operators.Overhead–Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set-up costs, indirect material,expendable tools, maintenance, property taxes, insurance onassets, and utility costs. Factory overhead does not include selling, general, and administrative costs (SG&A); research and development (R&D); interest; or profit (accounted for by DOE separately).Full Production Cost= Direct Material + Direct Labor + Overhead (factory) + DepreciationFull Cost of Product= Full Production Cost + Non-production Costs (SG&A, R&D, interest, and profit)5-A-10Table A2-9: Portable Air-Conditioner Shipment DataYearTotal SalesPercent of Sales by Different CondenserPercent of Sales withAir Duct ConfigurationsCondensate ReSingle DuctTwo-DuctOtherevaporation Capability20002001200220032004200520062007Table A2-10: Portable Air-Conditioner Capacity DataCapacity Range (Btu/hr)Percent of Sales for a RecentYear (2006 or 2007)Less than 6,0006,000 to 7,9998,000 to 13,99914,000 to 19,99920,000 or more5-A-11

# 5-A.3 DATA REQUESTS FOR STANDARDS RULEMAKING FOR

RESIDENTIAL CLOTHES DRYERS AND ROOM AIR-CONDITIONERS

5-A-12

# Data Requests for Standards Rulemaking for Residential

Clothes Dryers and Room Air-Conditioners

– 01/09/2009

Clothes Dryers

1. Shipment-weighted average remaining moisture content (RMC) over time for

residential clothes washers for top -loading units, front-loading units, and

combined.

2. Data regarding consumer usage patterns for residential clothes dryers- the # of

annual use cycles. Preferably the number of dryer use cycles independent of wash

cycles. If not, then the % of loads washed that are machine dried.

3. Has AHAM made any progress on the development of a clothes dryer test

procedure which tests dryer opera tion using automatic termination?

4. Is AHAM developing test methodology for condensing dryers?

Room Air Conditioners

1. Data regarding consumer usage patterns

– room air-conditioner annual hours of

operation.

5-A-13